Polymerization of olefins in halogencontaining diluent



POLYMERIZATION OF OLEFINS IN HALOGEN- CONTAINING DILUENT James T, Edmonds, In, Bartlesville, Okla, assignor to Phillips Petroleum Company, a corporation of Delaware No'firafi'ing'. Filed'Nov'. 25; 1957, Ser. No.- 698,371 3 (trains. or. zen-94.9

This invention relates-to the polymerization of olefins. In one aspect, the invention relates to a method for polymerizing olefins in the presence of a halogen-containing diluent. In another aspect, the invention relates to a novel catalyst for use in the polymerization of olefins in the presence of a halogen-containing diluent,

Reactions for polymerizing olefins are Well known in the art and are generally carried out in the presence of catalysts. One' class of catalysts which has been used in the polymerization of monoolefins, particularly ethylene, is organometal compounds, for example, triethylaluminum, and the-polymers which have been obtained in accordance with this method are generally liquid or low molecular weight solid polymers. It has been reretested July 5,19 9:

l ingtothe formula R MX wherein Rain are as indi:

cently discovered, as disclosed in the copending U.S; 1

patent application of J-. P. Hogan and R. L. Banks, Serial No. 513,877, filedMarch 26,1956, nowissued as U.S.

Patent 2,825,721, that'unique polymers and copolymers can be produced by contacting one or more olefins with a catalyst comprising; as an essential ingredient, chromium? oxide, preferablyincludinga substantial amountof hexavalent chromium. The chromium oxide is ordinarily associated-with at least one .other oxide, particularlyat cated hereinbefore, X is a halogen, including chlorine, bromine, fluorine and iodine, and wherein x, and y are integers, the sum of x and y being equal to the valence of metal M.

The chromium oxide-containing component of my catalyst system canbe prepared by preparation methods which are known in the art, e.g., direct mixing of solid components, impregnation, etc. In order to obtain opti mum activity, it is preferred that the component 601111 prising chromium oxide and the additional oxide as hereinbefqre specifiedbe-heated under elevated temperature and fora sufficient time to activate, or increase the activity of, the component for the polymerization reaction. It is also preferred that the catalyst component comprising chromium oxide and the additional oxide be heated under non-reducing. conditions in an atmosphere such as oxygen, air, nitrogen, carbon dioxide, helium,

argon, krypton, or xenon. Reducing gases such as hydrogen or carbonmonoxide can be present in the atmosphere where the time of contact, especially at the higher temperatures, is limited to prevent extensive reduction of the hexavalent chromium; however, the presence of such gases, and of reducing agents in general, is ordina1i- 1y not desired. It is usually preferred that the activation atmosphere be non-reducing. It is further preferred that theatmosphere. be positively oxidizing, e.g., air or oxygen. The temperature and time of activation can vary, over" wide ranges and are closely inter-related (So-called time-temperature efrect), longer times being. required at lower temperatures and shorter times atghigher ternperatures. Catalyst components prepared milling.

- solid -siliea-alumina; zirconia and/or thoria: with solid least one oxide selected from the group consisting. of

silica,- alumina, zirconia and thcria. Whenthe abovedescribed processes are carried out in the liquid phase, a hydrocarbon diluent, inert and.- liquid -under conditions of the process, is used Inaecordance with the instant invention, a novelrcatal'yst composition is provided which" is efiective in polymerizing olefinsto solid polymersin the presence of halogen-containingfdiluents. 7

It is an object of the invention; therefore, to provide a novel process for polymerizing olefins in the presence ofa halogen-containing diluent.

Another object of the invention is to provide a novel catalyst for use in polymerizing olefins in the presence of a halog'en-containing diluent. a Other and further objects and advantages of the invention will become apparentto those skilled inthe art upon consideration of the accompanying disclosure.

. The present invention resides inthe discovery that a solid polymer is obtained when an olefin, such as ethylerie, is contacted in the presence ot a halogen-containing.

the formula MR' wherein M is a metal selectedtrom.

the group consisting of boron, aluminum, gallium, indium, thallium,.zin'c, beryllium and magnesium, wherein R is at least one member .selectdfiom the group consisting of emigrated acyclic hydrocarbon radieais earn: rated cyclic hydrocarbon radicals, and aromati hydru carbon radicals, and wherein n is equal to the valence of metal M, and (b) an organometal halide correspond chromium oxide are a ct-ivatable at lower temperatures than are catalyst components prepared by: impregnating silica;alumina, zircoin'a and/or, thoriawith an aqueous solution of achromiumcompound, As atpractical} mat-f ter, a chromium oxide catalystcomponent preparedby dry mixing is ordinarily activated at a temperature of at least about 350? F. and not substantiallygreater than about 1500? F. A component prepared byimpreg nations with an aqueous solution is ordinarily-activated at a temperature of at least 450 F; and notsubstantiallykgreaten than l5 00 F; Times of activation ca'n ra nge from-about a second at the highest temperatures to' 50. hon-rsor more at the lowest temperatures. The stated numerical values ar'elgiven as illustrative of tlie most practical. ranges and a'r'eflrio't absolute limits; By using very short times and; higher temperatures, orvery long times and lower tentperatures, catalyst components hav by calcination, followedby drying and activation ofthe" composite. at a temperature in the range of 4 50 1015QQe:

dew-point -of the activation gas should be'below F,,

more desirably below ;zero-.- I However, ;inert gasesgsuclr;

as carbon dioxide and nitrogen can be used; The catalyst component; comprising chromium oxide can be prepared: using, as a starting'material; chromium trioxide, chromic nitrate, chromic. acetate, 'chr'omic chloride, chromic sulsfate, ammonium chromate, ammonium dichromate, se

dium' dichromate, lithium chromate,-or other soluble/saltsing various degrees of increased activation are obtainable. Thecliromium oxide. catalyst compo iler'it can be pro-: pared by impregnation of: particulate silica, alumina or; V silica-alumina, for example, with a solution of chromiunr trioxide or a compound convertible to chromiu m oxide;

V ,iri' Xis a Halogen." Thexand ygare 1n .naaieal having-*1 m um ,oxiderinthe catalyst component can range from mar more weight percent, and is ordinarily a minor 'the process :of this invention are preferably 1 aliphatic component of the 'catalyst component i'n'terms'of weight i 7 percent. A preferred non-chromium component or support is a silica-alumina composite containmg a ma or pr 0.

port ion of silica and a minor proportion ofalumina'. While the method of preparing the silica-alumina composite undoubtedly afie'cts the catalyst activity to some extent, it

appears that silica-alumina composites prepared by any of the'prior art processes for preparing such catalytically invention. Copr'ecipitation and impregnation are examples" of such processes. One support that has been found particularly effective is a coprecipitated.90 percent silica' lO percent alumina support. It is necessary .for some of the chromium to be in the hexavalentstate, and it is preferred'to use a chromiumoxide catalyst'component infwhich the amount of hexavalentchromium is'at least 7 L 0.1 percent of the weight of the catalyst component comprising the chromium oxide and associated oxide or oxides." The hexavalent chromium is determined by ase'rtaining the water soluble chromium present by leaching with water and determining the dissolved chromium in the leachingsby any suitable analytical method known in a the art,je.g., addition of potassium iodide solution and titration of the liberated iodine with sodium thiosulfate solution. r V t r is admixture with the chromium oxide'component describedabove, my noveltcatalyst system comprises a compound corresponding to' the'formula MR wherein M is one of the metals'boron, aluminum, galliumgiindium,

urated' acyclic hydrocarbon tradical, a saturated cyclic hydrocarbon-radical, or an aromatic hydrocarbon radical a a a a 35 or any combination thereof, and wherein n' is equal to the like." a

. t iAlternatively, or in-additionto the MR;, compounds set forth above, my catalyst systemcomprises a :mixtureof theabove-described chromium' oxidefcatalyst component I andat least one organometal halidecorresponding to the forniulaRgMX}, wherein M and R are as described here inbfore' with relation to the MR' compounds, and where- .v t v r of Jr andis'equal; to the valence'o bon -radicals-liaving up to aboutzo carbon atoms each.

77 0 carbon atoms 'or less aret preferre d' "-th'e resulting= catalyst;compositiodhas a greater iihkfideicm used n i YM alyst-com h followin en -B61 0,11 3%, o m um,

es 'rs vand t ii' um V l m l X "be i ofiany 1 of the halogens, includingfchlorine, bromine; iodine; and fluorine. The saturated acyclici hydrocarbon "ggradicals, saturated cyclic hydrocarbon radicals and TI IIO-j.-

" a magi hydrocarbon radicals, which can be 'substituted'for' in either the" MR, or R -M'X formulas, include hydrot Specific examples ofiother torganometalhalides? Vf h chare-usefulinth ;c'atal ystcomposition of this inven-Q l "l actiye composites 'are operative for the process of this a Lolefins having up to and including 8 carbon atoms per 5 molecule. 7 include ethylene, propylene, l-hexene, and l-octene. It is Examples .of such olefinswhich can 'be used Broadly speaking, the halogen-containing diluents used 1 in the practice of thisinvention can be halogenated com j pounds resulting from the halogenation of aliphatic, cycloaliphatic and aromatic hydrocarbons. Examples of spe cific halogen-containing diluents include carbon tetra- V chloride, tetrachloroethane, methylene chloride, chloroform, chlorobenzene, monochlorocyclohexane, and the like. The amount of the catalyst composition of this invention which is used in the polymerization of olefius can vary over a wide range. Relatively small amounts of the catalyst provide the desired activating effect whenv the polymerization reaction is carried out as a batch process with continuous addition of theolefin as the polymeriza-' tion reaction occurs. When a continuous flow system is employed, the concentration ofthe total catalyst com position is usually in the range from 0.01 weight percent to 1.0 'weight percent, or higher. 7 v 7 V a The amount of the organometal compound present in the catalyst system is preferablyfat least one percent by 1 weight ,of the amount'of the catalyst component com prising chromium oxide and the additional oxide. While thallium, zincfheryllium, ormagn'esium, and R is asat- 7 there is nofupper limit in'the amount of the organ'o' co -g pound which can be employed, the preferred tange -is from. 0. 5j to 5 parts by weig'ht per-part ofthe chromium} oxide catalyst component. .Th'e polym'eriz'ation of ,olefins iat si s a f e n ta t ,sata v 's' m iS carri d. outfata temperature in the range ot zero @1250 F; ,wh

the'pressure' is usually in the range lo to 1006 p.

' vdesired, the, preferred: pressure range is 1 between 1001 .1 7331121 500 p.s.i.g. V i

i "The process of this invention ean'be carriedioultQa sa batch process by pressuring the olefin into a reactor co ns K I vtainin'g' the. catalyst and. halogen-containing diluent,

Furthermore, the processcan' bevcarriedout continuous 'ly maintaining-the above -describ'ed'concent'rations of reactants in the" reactor for a suitable residence time Theresidence time used in a continuous' 'process can,

vary widely, since it depends to a great extent upon the temperature. at which. the process conducted. The

residence time also varies the particular olefinthat '7 is being polymerized. However; theresidence time generally falls within the range of 1 second to an hour or Y j more, In the batch process, the time-for the reaction can also varywidely, suchl t up to 24 hours or mars. been found that various materialsinysoniein stances. may have a tendency to inactivate the catalyst] compositions of this'invention. These materials include carbon dioxide, oxygen and water. Therefore, ;it, is" usually desirable .to. free the olefin to hepolymerized from these materials',ras well as fromotherjmatei-ials' which 'inayrtend to inactivate the catalyst before 6011- tasting the; olefin with the catalyst. Anyof thelknown means to: removing such contaminants canghe employed, 1 Furthermore the diluent should g nerallybelfrced' of i contaminantgsuch as water, oxygen,'. and the like. I It'is desirable, also, that air andmoisture .beremoved-ffi'iqm' activating materials, ,suchas oxygenor Water, .dan be} stoodthatthe'amount ofisuch materials present in the reaction mixture shall not be suflicient, to completely inactiva e the cataly At the completion of the polymerization reaction, when a batch process is used, the reactor is cooled-to about mom temp atme a y ex s olefin is ve te an the contents ofthe reactor, including the solid polymer swollen with diluent, is then treated to inactivate the catalyst, as by washing with an-alcohol. The alcoholwashing step is preferably carried out in a comminution zone, such .as a Waring Blendor, so that a finely-divided polymer is thereby provided. The polymer is then separated from the alcohol and diluent by decantation or filtration and then the polymer is dried. in a preferred method of operation, the polymer while in solution in a diluent is washed with water after which the solution is passed through a filter. The polymer, which is then precipitated from solution e.g., by the addition of a suitable percipitation agent, such as alcohol or water, is recovered by any suitable means, such as filtration or decantation. This method is effective in removing substantially all of the catalyst from the polymer. 'When the process of the invention is carried out continuously, the total efiiuent from the reactor, including polymer, diluent and catalyst system is pumped from the reactor as a slurry to a catalyst-inactivating zone where the reactor eifiuent is cooled and contacted with a suitable catalyst-inactivating material, such as an alcohol, to precipitate the polymer. As in the batch process, it is de sirable that the alcohol-treatment step be carried out in a comminution zone so that a finely divided polymer is thereby produced. The diluent and alcohol are then separated from the polymer, for example by filtration and the polymer is then dried. The diluent and alcohol can be separated, for example by fractional distillation, and reused in'the process. The polymer can also be subjected to a water-washing step while in solution and then filtered as previously described in order to separate catalyst from the polymer.

A more comprehensive understanding of the invention can be obtained by referring to the following illustrative examples which are not intended, however, to be unduly limitative of the invention.

EXAMPLE 1 A silica-alumina composite containing 87 weight percent silica and 13 weight percent alumina was impregnated with chromic nitrate. The resulting catalyst component which contained 2.5 weight percent chromium was activated in an oxidizing atmosphere by heating in air of a dew point less than zero to 1125 F. for hours. The total activation time, i.e., the time from the initial application of heat until cooling, was 24 hours. 7

Eighteen hundred milliliters of reagent grade carbon tetrachloride, which had been previously dried over silicaalumina, was charged to a 2700 milliliter stainless steel rocking autoclave bomb. Prepurified nitrogen was bubbled through the carbon tetrachloride for 10 minutes, after which 70 grams of the above-described chromium oxide containing catalyst component was charged to the bomb. The bomb was then pressured to 100 psig with pure grade ethylene. For bomb temperature remained constant at 85 F. for 80 minutes during which time no substantial changes in bomb pressure were noted.

.The bomb pressurewas then bled down to 60 p.s.i.g.,

and the bomb was heated by means of an electrical heater. After a period of 125 minutes, the bomb temperature'had reached 205 F., at which temperature the pressure was 110 p.s.i.g. After an additional 215 minutes, the temperature of the bomb was 150 F. and the pressure Was 90 p.s.i.g. The heat was then turned off, and the bomb was vented and opened. No solid polymer was present in the bomb.-

EXAMPLE 11 Eight hundred milliliters of reagent grade carbon tetrachloride, which had been dried over silica-alumina, was charged to the autoclave bomb described in Example I. Prepurified nitrogen was then bubbled through the carhon-tetrachloride for .10 m: utes, after which ,50 ml. of a solution oftriisobutylaluminum in cyclohexane, which contained 0.25 gram of triisobutylaluminum per milliliter, was charged to the bomb. The bomb was then pressured to 50 p.s.i.-g. with pure grade ethylene, .the temperature at this time being ,F. The bomb was rocked for 5 hours and- 45 minutes at this temperature, during which time one repressurization with ethylene was necessary. When the bomb was opened after venting the ethylene, a trace, i.e., an immeasurably small amount, of solid polymer wasfound.

EXAMPLE III Eight hundred milliliters of reagent grade carbon tetrachloride which had been driedover activated silicaalumina was charged to the autoclave bomb described in Example I. Prepurified nitrogen was bubbled through the carbon tetrachloride. Twenty grams of the chromium oxide-containing catalyst component of Example I and 40 ml. of a solution of triisobutylaluminum in cyclehexane, which contained 0.25 gram of triisobutylaluminum per milliliter, were charged to the bomb. The bomb was then flushed with nitrogen, closed, .and pressured to p.s.i.g. with pure grade ethylene :which had been previously dried over activated silica-alumina. The polymerization which was immediately initiated at room temperature was allowed to continue for 4 hours and 30 minutes during which time the temperature gradually increased from an initial value of 85 F. .to .a maximum of 110 F. and gradually decreased to F. at the end of the run. It was necessary to repressure the bomb to 100 p.s.i.g. with additional ethylene on 12 different occasions during the course of the run. At the end of this time, the pressure was vented from the bomb,

solved in 5 liters of cyclohexane at 300 F. under nitro-' gen pressure. Thereafter, the solution was charged to a six-gallon stainless steel vessel which was equipped with a stirrer. This solution was then passed through a Cuno filter which was equipped with a glass filter cartridge. The glass filter cartridge had been previously precoated with 60 grams of Celite 512 filter aid. During the filtration, the filter was maintained at 300 F. by means of an electrical heater. After the solution had been filtered, the solvent was flashed oif under vacuum, and the polymer. which was present was dried overnight at 65 C. (149 F.) under vacuum. One hundred and one grams of dry polymer were obtained. The properties of this dry polymer are set forth hereinbelow in Table I.

1 ASTM D123852T. 2 ASTM D256-54T. ASTM D412-51T.

EXAMPLE IV A run was carried out following essentially the .same procedure described in Example III. In this run, 1600 ml. of reagent grade carbon tetrachloride, which had gen through the carbon tetrachloride, 15 grams of the I I chromium oxide containing catalyst component, prepare'cl'as described in Ex'ample I, and 30 ml. of-a hydroc'arbon' solution of triis'obutylaluminum, similar to: that used in Example III, was charged to the reactor After flushingwith prepurified nitrogen," the autoclave was a pressured, to1 9 p.'s.i.g. with puregrade ethylenefwhich 7 had. been previously purified by passing through, an alkaline pyrogallol solution and: overactiyated silicaalumina. The polymerization run wh ichwasimmediately initiatedat roomternperature was continued for aperiod of 11 hours; during which the temperature varied between 75 and 100 The major portion of this run was carried out at a temperature'of. 95 F. As the pressure droppeddue .to the polymerization, additionalethylene was pressured into the. autoclave to raise the reactor *1 .pressureto betweenllo and 130'p.s.i;g. .During this run, it'is necessary to add additional ethylene'every 10 'to ISminuteS. Atthe end of the 11-hour period, the

autoclave was allowed tov stand for .10 hours and 35 minutes after which it was'noted that the temperature was 65' F. and the pressure was 35 p.s.i.g. The autoclave was then vented and opened, and the polymer contained therein was washed twice in' methyl alcohol. After drying this polymer, overnight ina .vacuum oven at 60 C., 170'grams of dry solid polymer was recovered.

The polymers and copolymersproducedin accordance with this invention have utility in applications where solid plastics are used. They canbe molded to form articles tetrachloride'at a temperature in the range of zero to be apparent to those skilled 1n the art upon consideration 1 0f the foregoing. disclosure. Such modifications and variations ,are believed to be clearly within the spirit and" scope of the invention. P g a l'claimzqfl' LA method and alumina and triisobutylaluminum, the amount'offti-i- 'isobutylaluminum in said catalyst'being inthe range; "of 0'.5 to 5 parts by weight per part of said chromiumfixide and saidfsilica and alumina,.sa'id contacting occurring in the presence of: carbon tetrachloride at a temperature in the range of zero to250" F and a pressure in the range ofiOO to 500 p.s.i.g.; and recovering the solid'polymer V of ethylene so produced.

2. A method for polymerizing ethylene whi chconn i prises contacting ethylene with a'catalyst consisting essentially of 1) chromium oxide, at least part of the;

chromium being in, the heXavalent state, supported on silica and alumina, and (2) a compound havingthe for mula AlR3, whereinjR is an'alk yl radical having up 'to 20 carbon atoms, the amount of the AlR compound in said catalyst being in the range of 0.5 to.5 parts by weight per part of said chromium oxide. and said silica and alumina, said contacting occurring in the presence of carbon 250 F.,and a pressure in the range of lO O to 500 p.s.i.g.

. 3. A method according to claim 1 wherein said AIR compound is triethylaiuminum. 7

References Cited the file of this patent I V UNITED STATES PATENTS' 2,824,989 Peters et a1. r Feb. 18, 1958 ,FOREIGN'PATENTS 534,792 7 Belgium Jan 31,1195

for polymerizing ethylene iyvhich com prises contacting ethylene] with a" catalystf consisting' essentially of; chromiumoxide, at leastpartjof the cliiomium being in'the hexavalentstate, supported on gsilica UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 2,944,049 July 5, 1960 James T. Edmonds Jr.

It is hereby certified that error appears in the printed specification of the above numbered patent requiring correction and that the said Letters Patent should read as corrected below.

Column 8, line 28 for the claim reference numeral "1'' read 2 Signed and sealed this 31st day of January 1961.

SEAL) Attest:

KARL a. AXLINE' ROBERT c. WATSON Attesting Oflicer Commissioner of Patents 

2. A METHOD FOR POLYMERIZING EHTYLENE WHICH COMPRISES CONTACTING ETHYLENE WITH A CATALYST CONSISTING ESSENTIALLY OF (1) CHROMIUM OXIDE, AT LEAST PART OF THE CHROMIUM BEING IN THE HEXAVALENT STATE, SUPPORTED ON SILICA AND ALUMINA, AND (2) A COMPOUND HAVING THE FORMULA AIR3, WHEREIN R IS AN ALKYL RADICAL HAVING UP TO 20 CARBON ATOMS, THE AMOUNT OF THE AIR3 COMPOUND IN SAID CATALYST BEING IN THE RANGE OF 0.5 TO 5 PARTS BY WEIGHT PER PART OF SAID CHROMIUM OXIDE AND SAID SILICA AND ALUMINA, SAID CONTACTING OCCURRING IN THE PRESENCE OF CARBON TETRACHLORIDE AT A TEMPERATURE IN THE RANGE OF ZERO TO 250*F. AND A PRESSURE IN THE RANGE OF 100 TO 500 P.S.I.G. 